Molded container head with orifice valve

ABSTRACT

The present invention is a molded container head with an orifice valve contiguously molded from a single piece of material. The instant container head assembly is an improvement over existing orifice valves as it can be formed during the molding of the container or container cap.

BACKGROUND OF THE INVENTION

Squeeze tube and bottle containers are used to package and dispensenumerous flowable substances, such as powders, pastes or liquids.Application of pressure on the sidewall of the container dispenses aflowable substance from an orifice in a neck formed on the container. Incertain instances, it is desirable to use a self-sealing or self-closingvalve in combination with a container. Examples of such containerscontaining self-sealing valves are, for example, described in U.S. Pat.No. 5,033,655 and U.S. Pat. No. 5,213,236. As described in thesepatents, a dispensing package may contain a self-sealing valve whichsecurely seals upon cessation of pressure on the side wall of thecontainer, so as to protect the contents thereof from the atmosphere,but upon squeezing of the side wall the contents will be dispensed.

The use of a self-sealing valve in combination with a tube shapedcontainer is suggested in U.S. Pat. No. 5,033,655. In order to use sucha self-sealing valve in a tubular container, however, the side wall ofthe tubular container must have a specific rigidity or thickness suchthat, while being squeezable, the side wall will return to the shapethat existed before squeezing such that air will be sucked back into thecontainer body so as to close the self-sealing valve. The formation ofsuch thick-walled tubular containers is expensive and requires specialequipment.

U.S. Pat. No. 5,911,344 discloses a rigid thermoplastic squeezecontainer having a self-sealing dispensing valve, for use with flowablesubstances, wherein the container has a cylindrical shell with a bodyportion, a first sealable open end and an opposite end having a headportion with a dispensing orifice closed off by a self-sealing valve. Athermoplastic cylindrical support sleeve is fitted within thecylindrical body portion which extends from a position adjacent to thehead portion to a location spaced from the sealable end of thecylindrical body portion of the shell, such that the end can be sealed.

Dispensing valves for packaging containers are disclosed in U.S. Pat.Nos. 4,991,745; 5,033,655; 5,213,236; 5,339,995; 5,377,877; 5,409,144;and 5,439,143. However, the valves known in the art are neithereconomical nor efficient to produce because they are designed asseparate components which are inserted into the container orifice.

SUMMARY OF THE INVENTION

The present invention is a molded container head with an orifice valve,wherein the orifice valve and molded tube head are contiguously molded.In one embodiment, the present invention embraces a molded containerhead with orifice valve and container body. In particular embodiments,the molded container of the invention is produced by selecting amaterial and molding the material into a container head with an orificevalve.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of the molded container head and orificevalve.

FIG. 2 is a fragmentary top view of a concave orifice valve with across-cut slit aperture.

FIG. 3 is a sectional view of a concave orifice valve in the closedposition.

FIG. 4 is a fragmentary top view of a convex orifice valve with a singleslit aperture.

FIG. 5 is a sectional view of a convex orifice valve in the closedposition.

FIG. 6 is a fragmentary top view of a flat orifice valve with across-cut slits.

FIG. 7 is a sectional view of a flat orifice valve in the closedposition.

FIG. 8 is a sectional view of a flat orifice valve with acircumferential slit around the orifice depicted in the open position.

FIG. 9 is a sectional view of a container head assembly that iscontiguous with the body of the container.

FIG. 10 is a sectional view of a container head assembly that is anintegral part of the container cap and used in combination with astandard container.

FIG. 11 is a sectional view of a container head assembly produced as aseparate component and welded to a container body.

DETAILED DESCRIPTION OF THE INVENTION

As illustrated in FIG. 1, the present invention is a molded containerhead 10 contiguously molded with an orifice valve 12, which controls theflow of fluid 14 out of the container. As used herein, contiguouslymolded is intended to mean that the molded container head 10 and orificevalve 12 are molded from a single piece of material. The container head10 is intended to encompass the narrowed portion of a container throughwhich fluid from the container body is dispensed. Generally, thecontainer head encompasses the collar or neck region 16 of the containerand an orifice 18 located at the top 20 of the container head 10 throughwhich fluid 14 is dispensed. The container head 10 is typically referredto as the portion located above the shoulder 22 and body 24 portions ofthe container.

As used in the context of the present invention, a container is intendedto include squeeze tubes, squeeze bags, and squeezable bottles used forpackaging and dispensing non-solid products of the type which arecapable of flowing. Non-solid products include fluid or fluidizedmaterials, including liquids, pastes, powders, and the like, which arecollectively and generically referred to herein as fluids. Squeeze tubesor bags and squeezable bottles are flexible packages made from plasticmaterial (e.g., low or high density polyethylene, polypropylene,polyethylene terephthalate, polyvinyl chloride, softouch, dual layer, orcoextruded plastics), elastic material (e.g., silicone, thermoplasticelastomer, natural rubber, or synthetic rubber such as isoprene),laminate materials (ethylene vinyl alcohol resin), or combinationsthereof with one open end and one closed end. In particular embodiments,the container is a squeeze tube or bag formed by sealing a filled tubeat one end resulting in a package with a cylindrical, open end and aflattened, closed end (e.g., a toothpaste tube).

In one embodiment, the container head assembly 10 is integrated (i.e.,contiguous) with the shoulder 22 and body 24 of the container. As such,the shoulder 22 and body 24 of the container, container head 10 andorifice valve 12 are produced from a single piece of material to createa unitary one-piece construction. One configuration of this embodimentis illustrated in FIG. 1, wherein the container head assembly 10contains threads so that a cap or lid can be affixed to the container tocover the top portion 20 of the container. Another configuration of thisembodiment embraces a snap-on cap or flip-top cap affixed to thecontainer to cover the top portion 20 of the container head and orifice18. In another embodiment, the container head assembly 10 is integratedinto a container cap or lid which is affixed to the container. As such,the container lid or cap, container head 10 and orifice valve 12 areproduced from a single piece of material and affixed to the container.

As shown in FIGS. 2 though 7, the orifice valve 12 can be formed in avariety of configuration. For example, the orifice valve 12 face can beconcave (FIG. 3), convex (FIG. 5) or flat (FIG. 7) depending on flowproperties of the fluid 14 in the container. For example, a flat orificevalve face may be more suitable for proper dispensing of a highlyviscous fluid than the other orifice valve face configurations.

Apertures of the orifice valve 12 can take the form of a cross-cut slit26 (FIG. 2) which includes two, perpendicular, linear slits thatintersect at the center of the orifice valve; a single elongated slit 28(FIG. 4) that traverses the center or near-center portion of the orificevalve; a plurality of cross-cut slits 30 (FIG. 6) or parallel slits, ora 320° circumferential slit 32 extending around the orifice so that thevalve is, in operation, a flap covering the orifice (see FIG. 8). Slitsin the orifice valve are formed by slicing through the valve face,without removing any substantial amount of material therefrom, so thatvalve remains sealed when in the normal, fully closed position (see FIG.3, FIG. 5 and FIG. 7). The slit aperture of the orifice valve can beformed during the molding process or by the capping machine before thecontainer is capped. The length and location of slits can be adjusted tovary the predetermined opening and closing pressures of the valve,wherein slit apertures can be extend substantially from edge to edge ofthe valve face or constitute one or more pinpoint holes in the valveface. In operation, that orifice slits define flaps or pedals which flexinwardly and outwardly to selectively permit the flow of fluid productthrough the valve. In this regard, when the container is squeezed, fluidand air are displaced from the container creating a lower pressureinside the container versus the outside air pressure. This pressuredifferential causes the orifice valve to close after the container isreleased.

The orifice valve face configurations and apertures depicted in thefigures are exemplary for application with a variety of fluidviscosities and are by no way to be construed as limiting the possiblevalve face and aperture combinations. For example, the valve depicted inFIG. 3 is a suitable choice for a fluid with a viscosity in the range of300 to 500 centistokes. An orifice valve of design shown in FIG. 5 issuitable for use in combination with a fluid having a viscosity in therange of 100 to 200 centistokes, whereas the orifice valve depicted inFIG. 6 is useful in combination with a fluid having a viscosity lessthan 100 centistokes. As will be appreciated by the skilled artisan, anyorifice valve face configuration can be used in combination with anyaperture depending upon the fluid in the container and the amount andpattern of flow desired.

Another feature of the container head assembly is the thickness of theorifice valve relative to the container head. In general, the orificevalve is substantially thinner than the container head. In particularembodiments, the orifice valve 12 is a thin membrane with a thickness inthe range of approximately 0.05 mm to approximately 0.5 mm, wherein thecontainer head 10 is in the range of approximately 1.0 mm toapproximately 2.0 mm. In other embodiments the thickness of valve 12 isin the range of 1:5 to 1:2 relative to the thickness of container head10. The size and shape of the orifice valve in conjunction with thethickness and configuration of the adjacent container head material maybe varied in accordance with the viscosity and other physicalcharacteristics of the fluid being dispensed, as well as the desiredflow rate, flow pattern, threshold pressure, and sealing pressure. Theterm threshold pressure as used herein refers to the pressure in or onthe fluid product which will cause the valve orifice to shift from theclosed position to the outwardly open position. The force necessary toachieve the threshold pressure will be dependent upon the shape, size,rigidity, and material selected for the container and the valve. Allsuch factors are desirably balanced and adjusted to achieve the correctdispensing characteristics for the orifice valve.

In accordance with the present invention, the one-piece construction ofthe container head assembly is produced by selecting a suitable materialand compression molding, injection molding, or bi-injection molding(e.g., when employing a combination of materials) a container head 10with a thin valve 12 covering the orifice. As will be appreciated by theone of skill in the art, the material selected for producing the instantcontainer head assembly can be dependent upon several factors includingthe flow properties of the fluid being dispensed and whether thecontainer head assembly 10 is contiguous with the body of the container34 (FIG. 9), an integral part of the container cap or lid 36 used with astandard container 38 (FIG. 10), or produced as a separate component andwelded to the container body 40 (FIG. 11). Desirably, the materialselected for producing the container head assembly is resilient andflexible, retaining its physical and/or chemical characteristics inresponse to ambient changes such as temperature fluctuations, repeateduse, or exposure to active ingredients in the product. In this regard,the designed material flow rate and sealing pressure of any particularorifice valve will remain relatively constant. However, because thecontainer material or cap material is composed of the same material asthe orifice valve, it may be necessary to respectively select a morerigid container cap material or container body material suitable tostabilize the flexible material required of the orifice valve. Moreover,particular embodiments embrace the use of container body and orificevalve materials wherein the valve and container work together; the valveopening when the container is squeezed to dispense the product andclosing due to differential pressure and memory of the valve materialand shape after squeezing.

The instant container orifice valve formed contiguously with thecontainer head can replace valves that are molded separately andinserted in the head or cap as a separate piece. Molding the valve aspart of the container head eliminates the molding and assembly operationrequired when the valve is made separately. The instant container headassembly is used to control product flow, reduce leakage, and provide aclean orifice area because the valve cuts off the product flow therebypreventing stringing and product residue around to the orifice.Moreover, the container head assembly of the invention prevents air fromsucking back into the container and reacting with the product to spoilor otherwise degrade the product and reduce the product shelf-life. Assuch the orifice valve preserves the hygienic nature of the productduring repeated use. The container head assembly of the invention findsapplication in the packaging and dispensing of a variety of consumableor purchased goods or products including consumable products such aspersonal care products (e.g., soaps, shampoos, make-up, insectrepellents, and the like); first aid products (e.g., ointments,sunscreens, and the like); cleaners (e.g., detergents and cleaningsolutions); paints; and foodstuffs (e.g., yogurt, cheese-like products,jelly, oils, condiments, and the like). The instant invention is asignificant improvement in the manufacture of containers with orificevalves because the valve can be manufactured simultaneously with thecontainer thereby decreasing the cost and increasing the efficiency ofproduction.

1. A molded container head with an orifice valve, wherein the orificevalve and molded tube head are contiguously molded.
 2. The moldedcontainer head with orifice valve of claim 1, further comprising acontainer body.
 3. A method for producing a contiguously moldedcontainer head with an orifice valve comprising selecting a material andcontiguously molding the material into a container head with an orificevalve.